Electrical connector

ABSTRACT

The connector is formed with a longitudinal bore to receive the rectangular-shaped post as well as with a recess which extends either longitudinally or transversely of the bore. In either embodiment, the bore is in communication with the recess so that at least one of the sharp corners of the post projects into the recess and thus into an insulation coated wire disposed within the recess to form an electrical connection with the wire.

United States Patent [151 3,644,875

OLoughlin Feb. 22, 1972 [54] ELECTRICAL CONNECTOR 1,328,784 1/1920Benjamin et al. ..339/95 2,296,443 9/1942 Kleinfelder ...339/276 [721smch Hams 3,249,908 5/1966 Fuller et al ..339/98 [73] Assignee; Thomas8; Beflg Corporation, Elizabeth, 3,345,452 10/1967 Logan et al...339/276 NJ. Primary Examiner.loseph H. McGlynn [22] med: 1970Attorney-Thomas M. Marshall 21 A l. N .1 4 88 l 1 PP 9 ,3 57 ABSTRACT[52] us. Cl. 339/97 R, 339/273 R The is fmmed with IOhEihIdhIaI borereceive 511 int. Cl .1101.- 9/08 the mammal-shaped as as with a recesswhich [58] Field of Seam h .339/ 97-100 ends either bhghhdihhhYtransversely the hore- 5 57 53 174/95 R either embodiment, the bore isin communication with the recess so that at least one of the sharpcorners of the post projects into the recess and thus into an insulationcoated wire [56] References Cmd disposed within the recess to form anelectrical connection UNITED STATES PATENTS with the 177,318 5/1876Barbour ..339/273 11 Claims, 8 Drawing Figures PATENTED FEB 22 I972 l NVENTOR.

FRANCIS A. O'LOUGHLIN ATTORNEY 4 ELECTRICAL CONNECTOR This inventionrelates to an electrical connector. More particularly, this inventionrelates to an electrical connector for electrically and mechanicallyconnecting an insulated wire or magnet wire to a square or rectangularpost.

Heretofore, various connectors have been devised for connectingelectrical wires together. In many instances, in order to provide anefficient electrical contact between the two wires any insulation whichwas on the wires was stripped so as to expose the wires. Thereafter, theconnector was placed about the exposed portions of the conductors andcrimped or otherwise secured thereto. However, this stripping operationrequired time to perform and in some instances has led to destruction ofthe wire or other impairment of the wire due to improper manipulation ofthe stripping tools.

In order to overcome the disadvantages of stripping of the insulationfrom an insulated coated wire, various other techniques have been used.For example, various connectors have been devised with sharp pointswhich pierce through the insulation coating of a conductor into the wirelocated therein. These connectors, however, have generally been usedwhere one wire is being connected to a second wire. In the case where awire is to be connected to a post of substantial configuration andhardness, the use of a projecting sharp point has not been practical.Consequently, various types of solder joints have been used in order toconnect a wire to a post or a number of crimping steps have beenutilized'first to crimp a connector to a wire and second to connect theconnector to the post. However, the soldered joints have not always beenreliable and the latter technique requires a relatively great deal oftime and space.

Accordingly, it is an object of this invention to connect a wire to apost in a single operation.

It is another object of this invention to electrically connect aninsulation coated wire directly to a post.

It is another object of this invention to provide a simple and economictechnique of connecting insulated wires to posts.

Briefly, the invention provides a connector for forming a connectionbetween an insulated electrical conductor and a post having at least onesharp corner thereon. The connector is formed of a body of compressiblematerial, such as sintered powdered metal particles, having a bore whichextends longitudinally therethrough in order to slidably receive a posttherein. In addition, the connector body has a recess which extendsthrough the body adjacent to the bore so as to be in at least partialcommunication with the bore. This recess receives theinsulated'electrical conductor in facing relation to the sharp corner ofthe post. The connector is sized so as to initially slide over the postwith the conductor being received within the recess. Once the connectorhas been put in position on a post with the conductor therein, theconnector is compressed under a substantially circumferentially appliedload onto the post. As the connector deforms, the sharp comer of thepost projects into the recess containing the conductor such that thesharp corner passes through or pierces the coating of insulation of theconductor to electrically contact the wire or wires of the conductor.

In one embodiment, the connector is made in a substantially cubic formwith a rectangular-shaped bore passing longitudinally therethrough andwith a recess extending substantially transversely of the bore at oneend of the body of the connector. In this form, the conductor isdisposed transversely of the post upon compression of the connector ontothe post, the

sharp corner of the post pierces into a small segment of the conductor.

In another embodiment, the connector is formed with a here as above anda recess as above. However, the bore is disposed with respect to therecess such that a pair of sharp corners of the post project into theplane of the recess. In this embodiment, a pair of sharp corners of thepost pass through the coat of insulation of the conductor into contactwith the wire therein.

In still another embodiment of the invention, the connector has a boreand a recess which extend longitudinally therethrough in parallelrelation. The recess is sized to receive a conductor while the bore issized to receive the post. Upon compression of the connector onto thepost, a single sharp corner of the post pierces through the insulationcoating of the conductor to electrically contact the wire along alongitudinal axis or line.

In still another embodiment of the invention, a recess is disposedcentrally of the connector at one end while the bore for receiving thepost extends longitudinally through the bore laterally spaced from therecess. With this connector, the conductor is centrally placed in therecess either before or after the connector is slide over the post. Asabove, during compression of the connector onto the post, the sharpcorner of the post pierces into the insulation coating of the conductorto contact the wires therein.

These and other objects and advantages of the invention will become moreapparent from the following detailed description taken in conjunctionwith the accompanying drawings in which:

FIG. 1 illustrates an exploded perspective view of a connector and aconductor according to the invention;

FIG. 2 illustrates an exploded perspective view of a connector of theinvention with relation to a post and an insulation coated conductor;

FIG. 3 illustrates a connection made between the connector post andconductor of FIG. 2;

FIG. 4 illustrates a connection of a modified connector according to theinvention with a post and conductor;

FIG. 5 illustrates an exploded perspective view of another modifiedconnector of the invention with relation to a post and conductor;

FIG. 6 illustrates a plane view of the connector of FIG. 5 with aconductor in place;

FIG. 7 illustrates a connection made between the connector, conductorand post of FIG. 5; and

FIG. 8 illustrates a connection between a modified connector accordingto the invention with a post and a conductor.

Referring to FIG. 1, the connector 10 is constructed in a cubic form ofany suitable compressible material such as powdered metal particleswhich have been sintered together into a cohesive mass. The connector 10includes a central bore 11, for example, of rectangular configurationwhich passes longitudinally through the body of the connector 10. Inaddition, the connector 10 has a recess 12 which extends transverselythrough the body adjacent to the bore 11. The recess 12 communicates atleast partially with the bore 11 through a narrow slot 13 which iscommon to the wall 14 of the bore 11 and recess 12. More specifically,the plane of the bore 11 projects into the plane of the recess 12 at onecorner thereof.

The connector 10 is also provided with at least one groove 15 in a sidewhich communicates with the recess 12 so as to provide a strain reliefas described hereinafter.

The material of the connector I0 is such that the connector 10 can besubjected to a compressive force applied substantially circumferentiallyof the bore 11 so as to be deformed inwardly of itself to close up thebore 11 and recess 12. To this end, the connector 10 can be made of asintered mass of powder'ed metal particles such as copper, aluminum andcopper of any other suitably electricallyconductive metal or alloy. Inorder to fabricate the connector 10 into the appropriate shape, varioustypes of molds can be used. The techniques for fabricating such aconnector are known, as evidenced by U.S. Pat. No. 3,345,452, issuedOct. 3, I967.

Referring to FIGS. 2 and 3, in order to make a connection between a post16 and an insulated electrical conductor 17 having at least one wire 18and a coating of insulation 19 around the wire 18, the connector 10 isinitially made with the bore 11 of a shape to matingly slide onto andaround the post 16. Further, in this regard the post 16 is provided inany suitable shape with at least one sharp corner 20 thereon, forexample, the post 16 is formed as a square or rectangular post havingfour sides thereon. The recess 12 of the connector 10 is likewise sizedto receive the electrical conductor 17 therein in a recessed manner. Informing the connection, the electrical conductor 17 is initially placedinto the recess 12 in the connector with the end of the conductor 17being inserted into the grooves communicating with the recess 12 in asubstantially flush manner. Next, the connector 10 with the conductor 17seated therein is slid down onto the post 16. After the connector 10 ispositioned at a suitable point on the post 16 the connector 10 iscompressed onto the post 16 by a suitable tool exerting a substantiallycircumferentially compressive force on the connector 10 about the axisof the bore 11 and post 16.

Referring to FIG. 3, during compression of the connector 10 ontothe'post 16 the material of the connector 10 is caused to compressinwardly of itself causing a relative movement between the conductor 17in the recess 15 and the post 16 in the bore 11. As a result, the sharpcorner of the post 16 which is exposed to the recess 12 by way of theslot 13 begins to pierce or pass through the coating of insulation 19 ofthe conductor 17 and thereafter comes into electrical contact with thewire 18 within the coating of insulation 19. After the compressive forceis removed, a secure gastight efficient permanent electrical andmechanical connection is made between the conductor 17, connector 10 andpost 16.

It is noted that while the connector 10 can be of any suitable size withrespect to any suitable sized conductors and posts, the elements areusually of a relatively small size such that the degree of relativemovement between the recess and the bore of the connector duringcompression is also relatively small. That is, the degree of relativemovement need only approximate the thickness of the insulation coatingof the conductor so as to permit sufficient penetration of the sharpcorner of the post through the insulation coating into contact with theinternal wire.

Referring to FIG. 4, the connector 10 can be used so as to permit a pairof sharp corners 20 of a polygonal-shaped post 16 to pierce through theinsulation coating 19 of an electrical conductor 17. To this end, thebore 11 of the connector 10 which is shown as being a square is disposedwith two points projecting into the plane of the recess 12. In this way,as the connector 10 is compressed or otherwise crimped, the post 16having two sharp corners 20 projecting into the recess 12, the two sharpcorners 20 will pierce through or otherwise pass through the insulationcoating 19 of the conductor 17 into electrical contact with the wire orwires 18 therein. This connector 10 is otherwise constructed in asimilar manner as the connector described above with respect to FIG. 1.

Referring to FIGS. 5 to 7, the connector 21 can be modified so as tohave a bore 22 extend longitudinally therethrough to receive a post 23in sliding fit relation and with a recess 24 which extends substantiallyin parallel to the bore 22 while extending longitudinally through theconnector body. To this end, the recess 24 is shaped with a curvilinearcross section so as to receive an insulated electrical conductor 25therein. Accordingly, instead of being made in a cubic form theconnector 21 is made with a substantially random-shaped cross section soas to accommodate the rectangular-shaped bore 22 and the curvilinearrecess 24 therein.

Referring to FIG. 5, in order to made a connection between the squarepost 23 and insulated electrical conductor 25, the conductor 25 isinitially inserted into the connector 21 so as to be received within therecess 24 in a substantially snug fit manner. To this end, the recess 24may be slightly undersized so as to receive the conductor 25 or can besized to be the same size as the conductor 25 so that the conductor isreceived in a slip fit arrangement. Thereafter, the connector 21 withthe conductor 25 in place is slid down over post 23 so that one corner26 of the post 23 is in abutting contact with the outside surface of theconductor 25. Next, the connector 21 is compressed onto the post 23, asabove, so that the sharp corner 26 of the post passes through theinsulation coating 27 of the conductor 25 into electrical contact withthe wire 28 therein (FIG. 7).

, Referring to FIG; 8, the connector 30 can alternatively be made withthe recess 31 extending substantially centrally of one end of theconnector 30 with a bore 32 to receive a post 33 extending through aplane laterally spaced from the recess 31. As shown, the recess 31extends diametrically across the end of the connector 30 to receive aconductor 35 while the post 33 extends longitudinally through theconnector 30 with one corner 34 thereof projecting through the plane ofthe recess 31. In addition, the connector 30 can be provided with alongitudinal slot 36 to one side of the recess 31 opposite the bore 32.This slot 36 can function as a strain relief for the material of theconnector 30 as the connector 30 is compressed onto a post 33 or canfunction to receive a second conductor (not shown) having an exposedsection of wire therein. In either event, the connector 30 is utilizedin a similar manner as above. That is, the insulated conductor 35 isinserted into the recess 31 while the connector 30 is slid over the post33 which is received in the bore 32. Thereafter, as the connector 30 iscompressed onto the post 33, the exposed sharp corner 34 of the post 33pierces through the insulation coating 37 of the conductor 35 intoelectrical contact with the wire 38 therein. As shown, this connector 30is formed with a substantially cylindrical shape.

The invention thus provides a connector which can be used to readilyconnect an insulation coated wire to a post having a sharp cornerthereon. It is to be noted, however, that the sharpness of the corner ofthe post is related to the strength of the insulation coating such thatin the case where the coating has a minimal resistance against piercing,the corner of the post can approach a degree of bluntness.

It is also noted that the post is generally of a greater degree ofhardness than the electrical connector of the invention so as to permitthe connector to be compressed onto the post without deformation of thepost.

It is also noted that the various grooves or slots provided in theexterior periphery of the connectors described above can be used forstrain relief during compression of the connectors onto the variousposts described above.

What is claimed is:

1. A connector for mechanically and electrically connecting anelectrical conductor to a post having at least one sharp corner thereoncomprising a body of compressible material having a bore of rectangularcross section extending longitudinally therethrough to receive the post,and a recess extending transversely thereof to receive the conductortherein, with said bore having one corner thereof projecting into theplane of said recess, said corner of the bore being adapted to receivethe sharp corner of the post.

2. A connector as set forth in claim 1 wherein said body further has atleast one groove therein in communication with said recess to receive anend of the conductor therein.

3. A connector as set forth in claim 1 wherein said body is made ofsintered porous metal powder particles and is compressible under asubstantially circumferentially applied compressive force withoutfailure in compression.

4. A connector as set forth in claim 1 wherein said bore is disposedcentrally of said body and said recess is laterally spaced therefrom.

5. A connector as set forth in claim 1 wherein said recess is disposedcentrally of said body and said bore is laterally spaced therefrom.

6. A connector as set forth in claim 1 wherein said body further has aslot in the periphery thereof extending longitudinally of saidconnector.

7. In combination,

a post having at least one sharp corner thereon;

a connector having a bore therethrough receiving said post in matingrelation therein, and a recess adjacent said bore; and an insulatedelectrical conductor having at least one wire and a coating ofinsulation about said wire, said conductor being disposed in said recessof said connector and said sharp corner of said post passing throughsaid coating of insulation into electrical contact with said wire, saidconnector further including at least one strain relief groove receivingan end of said conductor therein.

a connector having a bore therethrough receiving said post in matingrelation therein, and a recess adjacent said bore, said bore having onecorner thereof projecting into the plane of said recess, said comer ofthe bore being adapted to receive the sharp corner of the post; and

an insulated electrical conductor having at least one wire and a coatingof insulation about said wire, said conductor being disposed in saidrecess of said connector and said sharp comer of said post passingthrough said coating of insulation into electrical contact with saidwire.

1. A connector for mechanically and electrically connecting anelectrical conductor to a post having at least one sharP corner thereoncomprising a body of compressible material having a bore of rectangularcross section extending longitudinally therethrough to receive the post,and a recess extending transversely thereof to receive the conductortherein, with said bore having one corner thereof projecting into theplane of said recess, said corner of the bore being adapted to receivethe sharp corner of the post.
 2. A connector as set forth in claim 1wherein said body further has at least one groove therein incommunication with said recess to receive an end of the conductortherein.
 3. A connector as set forth in claim 1 wherein said body ismade of sintered porous metal powder particles and is compressible undera substantially circumferentially applied compressive force withoutfailure in compression.
 4. A connector as set forth in claim 1 whereinsaid bore is disposed centrally of said body and said recess islaterally spaced therefrom.
 5. A connector as set forth in claim 1wherein said recess is disposed centrally of said body and said bore islaterally spaced therefrom.
 6. A connector as set forth in claim 1wherein said body further has a slot in the periphery thereof extendinglongitudinally of said connector.
 7. In combination, a post having atleast one sharp corner thereon; a connector having a bore therethroughreceiving said post in mating relation therein, and a recess adjacentsaid bore; and an insulated electrical conductor having at least onewire and a coating of insulation about said wire, said conductor beingdisposed in said recess of said connector and said sharp corner of saidpost passing through said coating of insulation into electrical contactwith said wire, said connector further including at least one strainrelief groove receiving an end of said conductor therein.
 8. Thecombination as set forth in claim 7 wherein said bore is disposed inparallel to said recess.
 9. The combination as set forth in claim 7wherein said recess extends transversely of said bore and said conductorextends at least partially transversely of said corner of said post. 10.The combination as set forth in claim 7 wherein said connector is madeof sintered porous metal powder particles and is compressible under asubstantially circumferentially applied compressive force withoutfailure in compression.
 11. In combination, a post having at least onesharp corner thereon; a connector having a bore therethrough receivingsaid post in mating relation therein, and a recess adjacent said bore,said bore having one corner thereof projecting into the plane of saidrecess, said corner of the bore being adapted to receive the sharpcorner of the post; and an insulated electrical conductor having atleast one wire and a coating of insulation about said wire, saidconductor being disposed in said recess of said connector and said sharpcorner of said post passing through said coating of insulation intoelectrical contact with said wire.